Vinyl slabs get underlayment in a continuous production proces.
In the industry of luxury vinyl tiles, one of the current trends is to have the underlayment or padding attached to the tiles in order to save time and effort when installing the floors. Avercon built a production line for Europe’s leading manufacturer of luxury vinyl tiles, that automatically glues the padding to large slabs of flooring – a process that requires a delicate control in drive technology to achieve perfect results.
In the production line the padding is coming from giant rolls while the large vinyl slabs are discrete. The delicate control in drive technology is to make sure that the slabs are perfectly aligned and following each other without intermittent gaps when the padding is attached.
The line get vinyl slabs from a crane in the warehouse which are unstacked by a portal that puts the slabs on a rotating arm to turn them upside down. From there the process starts to use conveyor segments with different speeds to get the slabs in acontinuous stream without gaps.
Meanwhile two rolls of substrate above the line are rolled off at a speed that gets synchronized with the speeds of the conveyor. Two rolls are needed to cover the full width of the slabs, meaning that the substrates too have to be perfectly aligned. After glue is applied to the slabs with a machine that got specially integrated by Avercon, the slabs and substrate are pushed together to become one product.
With both products combined, an optical system detects the divisions between the vinyl slabs to control a flying knife that separates them again by cutting through the padding. A winding barrel at the end of the line turns the slabs around before another portal robot picks them up for stacking. A transfer-system parallel to the line moves the product carriers back and forth between the unloading and the loading station. Integration with the warehouse control system makessure that all production steps get traced back to the individual orders and their storage locations.
“Thanks to a sophisticated synchronization of all moving parts, a high reliability got obtained, delivering excellent product quality. The production lines are the first to produce this kind of product on large vinyl slabs – a challenge that Avercon likes to take on”
A renowned manufacturer of luxury vinyl tiles, installed two lines to attach paddings to large slabs of vinyl flooring – one in the US and one in its production facility in Belgium. The latter provided Avercon with an additional challenge because the line is build on a platform that got installed with machines underneath in full operation.